钛种板与铜耳的电阻钎焊技术
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摘要
为实现钛种板与铜耳较大面积搭接方式的连接,本文应用自行改制的数控交流电阻焊机,采用性能良好的银基钎料及与之配合的钎剂对工业纯钛TA2与紫铜进行了电阻钎焊试验研究。结合正交分析,并经过多次试验成功实现了较大面积搭接试样的焊接,同时利用ANSYS软件对焊接温度场进行焊接过程的模拟,对拓展钛、铜焊接及电阻钎焊工艺的应用起到重要的推动作用。
结合正交分析,经过试验摸索出焊接尺寸为15mm×15mm×3mm的试样的最佳工艺参数为:附有氩气保护的条件下,焊接电流8KA、焊接时间90cycle、焊接压力0.4MPa。在此工艺参数条件下,接头剪切强度平均值可达到70Mpa以上。在做小样的同时对搭接面积为70mm×50mm的钛板和铜耳实施焊接,结果可以实现这种较大搭接面积的工件的焊接,并且焊缝结合情况良好,力学性能优良。
通过OM、EPMA等多种测试手段对焊缝结合情况进行了研究,发现钎料与母材结合良好,钎料中主要金属原子与母材Ti和Cu能相互扩散、浸润,达到了原子间微观结合,同时焊缝无明显缺陷。同时分析了焊接电流、焊接时间、焊接压力等参数对接头力学性能影响。
利用ANSYS软件对焊接温度场进行焊接过程的模拟。电阻钎焊过程是一涉及电、热、力、磁和冶金等问题的复杂过程,焊接过程的数值模拟也是一个涉及多变量、高耦合、非线性的动态问题。本文首先通过SolidWorks对焊接区建模,之后利用ANSYS软件对焊接过程进行了模拟,结果发现焊接过程的温度变化情况的数值模拟与试验值吻合良好。
经过以上研究工作,我们拟研发设计一套专门的钛种板与铜耳的电阻焊机,本文利用SolidWorks软件完成了焊机的初步设计方案,并对其进行了SolidWorks环境下的虚拟装配,同时利用Animator插件完成焊接过程的动画模拟。
In order to achieve the overlap link of the larger area between titanium plate and copper plate,we conducted some experiments to study resistance brazing technology of Ti and red copper,whose overlap area is larger,using the good performance of silver-based brazing filler metal and flux which was completed on the numerical control AC resistance welding machine.Taking advantage of orthogonal analysis,furthermore conducting repeatedly experiments,welding for specimen of larger overlap area was successfully realized.In the meanwhile,The temperature field simulation of the weld process is made by ANSYS software.It had the impetus function to develop the welding between titanium plate and copper plate and the apply of resistance brazing technology.
By means of orthogonal test and field testing repeatly,the optimized processing parameters for the specimen of 15mm×15mm×3mm was determined.It was shown by the result that,under argon shield circumstances,when the welding current was 8KA,the welding time was 90 cycle,the welding pressure was 0.4 MPa,shear strength of the single-lap joint was good performance,whose averages was over 90 Mpa.At the same time,we also weld the larger ones,whose overlap area was 70mm×50mm.The results show that we would achieve greater overlap area of workpiece and the mechanical property was good performance as long as the power of welding machine meet requirements.
The combination of weld joint was studied through OM,EPMA etc.The analysis results show that the connection between titanium plate and copper plate was good performance, diffudion and fusing happened between the main metal atoms of solder and the base metal Ti and Cu,reached microscopic connection and without defects.We also analyse the influence of welding parameters such as current,time and pressure on the mechanical properties of the joints.
The temperature field in the weld process was simulated by ANSYS software.The resistance brazing is a complicated process that relate to electricity,heat,mechanics, magnetism and metallurgy etc.The weld zone was modeled by SolidWorks,then the temperature field in the weld process was simulated of by ANSYS.In the result,the simulation of the temperature change in the weld process was inosculated with the experiment value.
We plan to make a special resistance welding machine to weld Ti and red copper.We have done the original design by SolidWorks,and achieve virtual assemblage by the SolidWorks. At the same time,we accomplish dynamic simulation of welding process by animator.
结合正交分析,经过试验摸索出焊接尺寸为15mm×15mm×3mm的试样的最佳工艺参数为:附有氩气保护的条件下,焊接电流8KA、焊接时间90cycle、焊接压力0.4MPa。在此工艺参数条件下,接头剪切强度平均值可达到70Mpa以上。在做小样的同时对搭接面积为70mm×50mm的钛板和铜耳实施焊接,结果可以实现这种较大搭接面积的工件的焊接,并且焊缝结合情况良好,力学性能优良。
通过OM、EPMA等多种测试手段对焊缝结合情况进行了研究,发现钎料与母材结合良好,钎料中主要金属原子与母材Ti和Cu能相互扩散、浸润,达到了原子间微观结合,同时焊缝无明显缺陷。同时分析了焊接电流、焊接时间、焊接压力等参数对接头力学性能影响。
利用ANSYS软件对焊接温度场进行焊接过程的模拟。电阻钎焊过程是一涉及电、热、力、磁和冶金等问题的复杂过程,焊接过程的数值模拟也是一个涉及多变量、高耦合、非线性的动态问题。本文首先通过SolidWorks对焊接区建模,之后利用ANSYS软件对焊接过程进行了模拟,结果发现焊接过程的温度变化情况的数值模拟与试验值吻合良好。
经过以上研究工作,我们拟研发设计一套专门的钛种板与铜耳的电阻焊机,本文利用SolidWorks软件完成了焊机的初步设计方案,并对其进行了SolidWorks环境下的虚拟装配,同时利用Animator插件完成焊接过程的动画模拟。
In order to achieve the overlap link of the larger area between titanium plate and copper plate,we conducted some experiments to study resistance brazing technology of Ti and red copper,whose overlap area is larger,using the good performance of silver-based brazing filler metal and flux which was completed on the numerical control AC resistance welding machine.Taking advantage of orthogonal analysis,furthermore conducting repeatedly experiments,welding for specimen of larger overlap area was successfully realized.In the meanwhile,The temperature field simulation of the weld process is made by ANSYS software.It had the impetus function to develop the welding between titanium plate and copper plate and the apply of resistance brazing technology.
By means of orthogonal test and field testing repeatly,the optimized processing parameters for the specimen of 15mm×15mm×3mm was determined.It was shown by the result that,under argon shield circumstances,when the welding current was 8KA,the welding time was 90 cycle,the welding pressure was 0.4 MPa,shear strength of the single-lap joint was good performance,whose averages was over 90 Mpa.At the same time,we also weld the larger ones,whose overlap area was 70mm×50mm.The results show that we would achieve greater overlap area of workpiece and the mechanical property was good performance as long as the power of welding machine meet requirements.
The combination of weld joint was studied through OM,EPMA etc.The analysis results show that the connection between titanium plate and copper plate was good performance, diffudion and fusing happened between the main metal atoms of solder and the base metal Ti and Cu,reached microscopic connection and without defects.We also analyse the influence of welding parameters such as current,time and pressure on the mechanical properties of the joints.
The temperature field in the weld process was simulated by ANSYS software.The resistance brazing is a complicated process that relate to electricity,heat,mechanics, magnetism and metallurgy etc.The weld zone was modeled by SolidWorks,then the temperature field in the weld process was simulated of by ANSYS.In the result,the simulation of the temperature change in the weld process was inosculated with the experiment value.
We plan to make a special resistance welding machine to weld Ti and red copper.We have done the original design by SolidWorks,and achieve virtual assemblage by the SolidWorks. At the same time,we accomplish dynamic simulation of welding process by animator.
引文
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[2]李志远.先进连接方法.北京:机械工业出版社,2000.
[3]潘春旭.异种钢及异种金属焊接.北京:人民交通出版社,2000.
[4]曲文卿,董峰等.异种材料的连接[J].航天制造技术,2006.3:44-49.
[5]王保华.影响异种金属焊接的主要因素.特钢技术,1996.2:19-22.
[6]李亚江,王娟,刘鹏.异种难焊材料的焊接及应用.北京:化学工业出版社[M],2004.1:1-4.
[7]邹僖主编.钎焊[M].北京:机械工业出版社,1989.
[8]赵越.钎焊技术及应用.北京:化学工业出版社.2004.3:1.
[9]N.K.Mukhopadhyay,S.Ghosh.Chowdhury,G.Dasetal.An investigation of thefailure of low pressure steam turbine blades.Engineering failure analysis,1998,5(3):181-193.
[10]Anatol Rabinkin.Brazing with amorphous foil performs.Advanced materials &processes,2001(6).
[11]石宝庆.钎焊技术发展动向[J].焊接技术,1998,1:37-38.
[12]吴全兴,闫安军.钛的钎焊[J].材料与工艺:1999.11:1-2.
[13]庄鸿寿,(联邦德国)E.罗格夏特(Lugscheider,E),高温钎焊[M].北京:国防工业出版社,1989.
[14]张启运,庄鸿寿主编.钎焊手册(Manual of Brazing and Soldering)[M].北京:机械工业出版社,1999.
[15]李瑞涛、方湄.虚拟样机技术的概念及应用.金属矿山[J],2000年第7期,15-19
[16]包金宇,廖文和.虚拟样机技术初探.机械制造与自动化[J],2003年第3期,1-4.
[17]姜士湖,闫相桢.虚拟样机技术及其在国内的应用前景.机械[J],2003年第30卷第2期,5-6
[18]曲文卿,董峰等.异种材料的钎焊技术.第十五届全国钎焊及特种连接技术交流会论文集,2007.10:1-7.
[19]张启运,庄鸿寿主编.钎焊手册(Manual of Brazing and Soldering)[M].北京:机械工业出版社,1999.
[20]常辉,罗国珍.钛合金用钎焊料的发展评述[J].稀有金属材料与工程,1995.2:15-20.
[21]#12
[22]Lugscheider E,Broich U.Mechanical properties of high-temperature brazed titanium materials,Welding journal,1995,74(5):169-s-176-s.
[23]Onzawa T,Suzumura A,Ko M W.Brazing of titanium using low melting point Ti-based 0 filler metals,Welding journal,1990,69(12):462-s-467-s,
[24]#12
[25]Norris B.The Development of Titanium Brazing Technologies.Sixth World Conference on Titanium.France,1988.
[26]Takemoto.T.,Nakamura.H.Okamoto I.Alu-minum Brazing Filler Metals for Making,Alumi-num to Titanium Joints in the Vacuum.Transac-tion of the JWRI,1990;19(1)39-41.
[27]Suezawa Y.A Study on Titanium Alloy Brazing with Silver and Zirconium Filler Metals.
[28]Takeshita.K.Takada.H.Low Temperature Brazing of Titanium with Ag-Al-Sn Filler Alloys.Journal of the Japan Institute of Metals 1991;55(3):330-336.
[29]Izue H.Suezawa.Y.Study on Ti-6A1-4V Alloy Brazed with Ag-5A!-0.5M n Filler Metal.Q.J.Jpn.Weld Soc.,1988;6(3)69-75.
[30]Heberard.X.,Hourcade.M.,Ferriere.G,Beauvais.C.,Hocheid B.,Low Temperature Braz-ing of Ti-6A1-4V Alloy.
[31]Takcmoto.T.,Nakamura.H.,Okamoto.I.Strength of Titanium Joints Brazed with A1Fillet Metals.Transaction of the JWRI,1990;19(1):45-49.
[32]虞觉奇等.二元合金状态集.上海:上海科学技术出版社,1987.
[33]何纯孝,周月华,王文娜.贵金属合金相图.北京:冶金工业出版社,1983.
[34]薛松柏,钱乙余.我国硬钎料生产中的质量问题及对策[J].焊接,1997(5):2-5.
[35]韩宪鹏,薛松柏等.无镉银钎料研究现状与发展趋势[J].焊接,2007.6:19-23.
[36]Weigert,Karl M.,"Formation and physical properties of metallaugical phases of the Ag-Cd-Cu-Zn quaternary alloy",Welding Joumal,34[J]420,1955.
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